System, method, and apparatus for leveling concrete and similar materials

ABSTRACT

A system, method, and apparatus for leveling concrete and similar materials. The automated, remotely controllable screed for leveling concrete can be used on any kind of sub-grade, it is lightweight and can be moved quickly to any location or floor level. It is highly accurate, and less labor intensive compared with the lightweight devices. It is all electrical mechanical. It is low noise. It is remotely controlled.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of priority of U.S. Provisional application No. 62/954,085, filed Dec. 27, 2019, the contents of which are herein incorporated by reference.

BACKGROUND OF THE INVENTION

The present invention relates to screeds, and more particularly to mechanical screeds for leveling concrete and other similar materials.

When a fluid slurry of concrete is poured, it is desirable that the finished hardened material form a surface, such as for floors, building foundations, roadways and other horizontal construction projects. The surface is formed to a desired grade and smoothness, depending on the application. Typically, a screed is utilized for this purpose.

Other screeds and systems either require manual labor to operate or, in the case of large horizontal construction projects, are very heavy towed or tractor driven devices.

Manually operated devices range from a simple hand screed that is similar in construction and operation to a pull rake. Vibratory screeds are similar in construction and operation to hand screeds with the inclusion of a vibratory devise powered by an electrical or mechanical motor. Others may operate like a lawnmower, but still require a laborer to drive the device. Still, others operate like tractors or large paving machines. The lightweight devices require much more manpower to get the suitable results and are subject to human errors.

The larger machines work well in certain circumstances, but they are very heavy and expensive. In most instances, the larger machines only work on a subfloor that is devoid of piping and reinforcement.

As can be seen, there is a need for an improved systems, methods, and apparatus to screed concrete that can be used on any kind of sub-grade, is lightweight, and can be moved quickly to any location or floor level.

SUMMARY OF THE INVENTION

In one aspect of the present invention, a powered screed for leveling a bed of a fluid concrete material to a desired grade is disclosed. The powered screed including a pair of rails dimensioned to extend across a lateral extent of a bed of concrete to be screeded. A plurality of support pedestals are configured to support the pair of rails in an elevated position above the bed of concrete. A power screed has a frame and a plurality of support rollers coupled to the frame. At least one of the plurality of support rollers is a drive roller. The plurality of support rollers are configured to movably carry the power screed on the pair of rails. The drive roller is engageable with the pair of rails to provide a motive force to move the power screed along a length of the pair of rails. A motor is coupled to a transmission assembly to rotate the drive roller. A main screed element is attached to a bottom of the frame. The main screed element oriented to screed across a longitudinal extent of the bed of concrete as the power screed traverses the pair of rails.

In some embodiments, a first linear actuator is coupled between the frame and the main screed element. The first linear actuator is operable to selectively raise or lower the main screed element relative to the bed of concrete.

In some embodiments, an expansion screed is coupled to the main screed element. The expansion screed is selectively extensible from the main screed element to expand a length of the main screed element to the longitudinal extent of the bed of concrete.

In some embodiments, a second linear actuator is coupled between the frame and the expansion screed, the second linear actuator operable to selectively extend and retract the expansion screed relative the main screed element.

In some embodiments, a foot moveably disposed on the frame. An actuator is coupled between the foot and the frame. The actuator is operable to selectively extend the foot to support the power screed on the foot and retract the foot so that the power screed may be supported on the pair of rails by the plurality of support rollers.

In some embodiments, a vibration module is attached to the main screed element. The vibration module is configured to deliver a vibratory force to the main screed element that is imparted to the bed of concrete.

In some embodiments, the plurality of support pedestals are vertically adjustable to orient the pair of rails in an alignment with a desired grade of the bed of concrete. A plurality of threads may be disposed at a top end of a pedestal shaft. A collar is threadingly engageable with the plurality of threads to adjust a vertical height of the collar relative to the pedestal shaft. A yoke is disposed at a top end of the plurality of support pedestals, the yoke having a top opening dimensioned to receive a transverse dimension of one of the pair of rails therein, and a downwardly extending cylindrical shaft having a bore dimensioned to receive the top end of the pedestal shaft, and a length to be supported on the collar.

In some embodiments, a base plate has an aperture defined in a top surface of the base plate, The aperture dimensioned to receive a bottom end of the pedestal shaft. The aperture may extend through the base plate. The bottom end of the pedestal shaft is received through the aperture and has a length to penetrate a ground surface subjacent to a bottom of the base plate. An annular rim may be defined around the bottom end of the pedestal shaft. The annular rim is positioned at a desired penetration depth of the pedestal shaft into the ground surface.

In some embodiments, a remote controller controls a direction and a rate of the drive roller.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is perspective view of an automated screed positioned over a bed of concrete.

FIG. 2 is a perspective view of a power screed component.

FIG. 3 is a side elevation cross sectional view of a pedestal support supporting a rail.

FIG. 4 is a detail cross sectional view of a yoke taken along line 5-5 of FIG. 3.

FIG. 5 is a side elevation cross sectional view of an alternative pedestal.

FIG. 6 illustrates a showing of the automated screed remote control panel.

FIG. 7 illustrates a side elevation view of a foot operation of the power screed.

DETAILED DESCRIPTION

The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense but is made merely for the purpose of illustrating the general principles of the invention.

Broadly, embodiments of the present invention provide a system, method, and apparatus to screed concrete and similar materials. An automated screed according to aspects of the present invention is a mechanical-electrical devise using a rail system to support and carry equipment to screed and level concrete and similar materials to a precise flatness and grade. Using a precise rail leveling system, which may include laser leveling, the system may be remotely controlled so that the operator may control the operation of the automated screed from a more advantageous vantage point. The automated screed is lightweight and very mobile. In some embodiments, it may be 100% electrically driven by battery or ac power. In other embodiments, it may be driven by an internal combustion engine. The automated screed operates above the concrete surface on movable rails that are anchored temporarily to the sub-floor.

The automated screed of the present invention can be used on any kind of sub-grade. Due to its lightweight construction, it can be moved quickly to any location or floor level in a structure.

As seen in reference to the drawings of FIGS. 1-9, the automated screed is carried on a pair of power rail frame which include a frame base 1, upright frame members 2, which are welded together creating a sub-frame. Each sub-frame is supported by a pair of rails 21 that extend across a lateral extent of a bed of concrete 30 to be screeded. The pair of rails 21 are supported by a rail support pedestal 20 disposed at opposed ends of each of the pair of rails 21. The rail support pedestals 20 adjustable in height and are set up to a desired grade, so that the rails 21 will be at the correct height to carry the power screed machine so that it screeds at a correct depth.

A main screed element 3 is operatively connected to opposed sides of the power rail frames. One or more expansion screed elements 4, 5 may be coupled to the main screed element 3 so that main screed element 3, and any necessary expansion screed elements span a longitudinal extent of the bed of concrete 30 to be screeded. The main screed element 3 may be welded to the power rail frame, while the expansion screed elements 4, 5 may be removably attached via a fastener, such as pins, bolts, or screws.

The power rail frame is supported on the rail 21 via a plurality of rollers 8, 9 that permit the power rail frame to traverse the rail 21 and draw the screed elements 3, 4, 5 across a surface of the concrete 30. The plurality of rollers may include one or more drive rollers that are operated by a motor 6, via a power transmission assembly. In the non-limiting embodiment shown, the power transmission assembly includes a drive chain 7, a drive roller wheel with sprockets 8, a reverse driver roller wheel with sprockets 9. The power transmission assembly may also include one or more chain idler wheels 10 with sprockets and one or more chain tensioners 11. The drive rollers with sprockets and bearings 8, 9 are interchangeable and are now bolted to the upright frame element 2. The chain idlers 10 and chain tensioners 11 may be bolted to the upright or main frame 1, 2 and the drive chain 7 is carried on the sprockets.

The motor 6, may be an electric dc motor that is bolted to the base frame 1. A motor control module 23 controls the direction and power of the motor. The motor control module 23, may be connected by wiring to a main control module 25 that is configured to control other operations and features of the automated screed. A power source 28 may also be carried on each power rail frame. In the case of a DC electric motor, the power source may include a battery. A converter-charger 26 may be wired to the batteries 28 and can be electrically attached to an ac electrical source to charge the battery 38. In the case of an internal combustion engine, the power source may include a fuel tank 28.

A plurality of first linear actuators or servos 12 may be attached to the upright frame 2 to the drive rollers 8,9 and wired to a laser control module 27 (optional) and the main control module 25. The first linear actuators 12 are operable to selectively raise or lower the position of the screed elements 3, 4, 5 relative to the concrete 30. The laser control module 27 provides for an alignment of the screed elements 3, 4, 5 to obtain a desired grade in the concrete 30.

A second linear actuator 13 is coupled between the main frame 1 and the expansion screeds 4, 5. With the expansion screeds 4, 5 carried on the main screed 3, operation of second linear actuator 13 selective extends or retracts the expansion screed 4, 5 along the longitudinal extend of the concrete 30. The second linear actuator is controlled by an expansion screed control 63 on the main control module 25.

A third linear actuator 14 is connected with a rail lifter 19 and are wired to a rail roller control 66 the main control module 25, to selectively extend and retract the rail rollers 19.

A fourth linear actuator 15 are connected to the feet 16 and are wired to a foot control 65 on the main control module 25 to selectively raise and lower the feet 16. The controls vibrators 24 are clamped or bolted to the main screed element 3 and wired to the main control module 25.

An outboard 17 and an inboard 18 transfer rollers are attached to the frame 1. The transfer rollers 17, 18 are oriented to transfer the power screed from a first pair of rails 21 to a second pair of rails 21, via a pair of transfer rails, disposed orthogonal to the first pair of rails 21. When the transfer rollers 17, 18 are supported on the transfer rails, the power screed may be rolled along the transfer rails to a position for mounting on the second pair of rails 21. The feet 16 may then be lowered to elevate the power screed and the second set of rails are positioned beneath the support rollers 8, 9. The feet 16 may then be elevated to place the power screed on the second set of support rails 21.

A vibrator 24 may be attached to each of the main screed elements 3. The vibrator 24 is configured to impart a vibratory pulse in the main screed element 3 and the screed extensions 4, 5 to facilitate screeding of the concrete 30. The vibrator is controlled by a vibrator control 69 on each of the main 25 and the remote-control module 60.

The main control module 25 may be controlled by the remote-control module 29. The remote-control module 29, shown in reference to FIG. 6 may be configured control the following actions:

-   -   1—controls motor 6 direction;     -   2—controls motor 6 speed;     -   3—controls extension and retraction of expansion screeds 5;     -   4—controls raise, lower, reverse, and forward, of the drive         rollers 9;     -   5—controls raise and lower the feet 16;     -   6—controls extension and retraction of rail rollers 19;     -   7—controls lateral motors 30 if used;     -   8—indicator views battery 28 charge state;     -   9 controls vibrators 24;     -   10—controls power ac, dc, on/off switch & lights; and     -   11—laser on/off switch & light.

The power screed, comprising its frames, screeds 3, 4, 5, and components are carried on the rails 21. The, which are used to power and/or drive the power screed forward, backward and sideways. The rails 21 are held in place by a pedestal pins 20 at a predetermined spacing, elevation, determined by the depth of concrete 30 material being screed, and width, and weight of the power screed.

The power screed can screed in any direction. The motors 6 and transmission assembly are configured to move the screed 3, 4, 6 in each of a forward, a backward direction and at different speeds, controlled by the motor controller 23, to move the drive chains 7, which in turn rotate the sprockets and drive rollers 8, 9 to move the power screed over the rails 21. The outside drive rollers 9 are not only rotated by the drive chain 7 but are elevated up and down by the linier actuator 12. These drive rollers 9 are configured to control an automatic reverse feature, an alternate forward and reverse feature, a rough grade feature, and an elevation of the screed to pass over an object protruding from the concrete 30.

The feet 16 may also be used to raise the power screed at an even higher elevation to pass over protruding objects by being pulled. The feet 16 are also used in conjunction with the rail extension rollers 19 to move and/or remove the drive rails 21 and to raise or lower the power screed to place it on or off the transfer rails 32.

A method of using the system may include:

The transporting the power screed power screed to a jobsite in subassemblies. In a non-limiting configuration, assemble 2-2″×4″/6″×16′ screed rails 21 and lay them on a flat surface approximately 16″ separated. Lay half frames with the open main screed 3 ends facing each other. Attach the expandable screeds 4, 5 main screeds 3 with included hardware. The power screed is then placed on the rails 21, though the power screed can also be assembled with the transfer rails 21 set on top of the screed rails.

Rail Setting. The rails 21 should be spaced according to the width of the power screed. Take the width of the power screed and add 3″ for a 2″ wide rail 21, and 2½″ for a 1½″ wide rail 21. That measurement will determine the center points for the width of the rails 21.

Drive or place the ¾″ pedestal pins 20 at a starting point and at the predetermined depth, determined by the depth of concrete material 30 being screeded and a width of the concrete 30. At an end point and set up 2¾″ pedestal pins 20 that are perpendicular and preferably squared to the starting pedestal pins 20. Run 2 string lines in parallel from the starting pins to the end pins. Place other pedestal pins (20) along the string lines at a predetermined spacing based on the weight of the power screed. Set the pedestals 20 to a predetermined grade, 18¾″ for a 4″ thick placement, using a laser or a very tight string line.

Using attached handles on each end, or a crane, position the power screed proximal to the beginning location. Using the power screed feet 16 raise the power screed above screed rails 21. Set 2 screed rails 21 perpendicular to a movement direction of the power screed on pedestals 10 and set the power screed on the screed rails 21 supported by the drive rollers 8, 9. Disconnect any cables connected to the power screed.

The operator may utilize the remote-control module 29 to ensure all controls, knobs, and switches are in a neutral position and position the power screed to the correct power source 28 to an operating condition.

If using a DC power source, check the battery charge to ensure a sufficient charge to screed the concrete 30. Check the orientation of the power screed, since it can work in either direction.

The operator may orient themself with a plurality of dots on the remote-control module 29 indicating a forward direction of the directional motor control 61 slowly to move the power screed to the starting point. The power screed is now ready to screed the selected material.

Extend the extension screeds 5 to the desired width of the concrete 30. Turn on vibrators 24 and adjust a vibrational speed of vibrations to a desired rate for the concrete 30 composition and desired finish. In some applications it is desirable to operate the screed controls 61, 62 in a rough mode by movement of the screed direction lever forward and make an initial pass to the end of the concrete 30 being leveled. Position the screed lever 61 to the neutral position and move the direction lever in the opposite direction to return to the starting point.

The power screed may be cycled through additional passes, with the direction lever 61 placed in a neutral position before changing direction. Don't worry if the power screed is moving too fast, or the material 30 is to stiff. In some embodiments the power screed may be maintained in a down on grade condition and the power screed will automatically reverse and return to grade and forward motion on its own.

When the expansion screeds 5 reach the pedestal 20 stop the traversal of the power screed to retract the leading expansion screeds 5 and move to trailing expansion screed 5 to the pedestal 20 and retract the trailing expansion screed 5 to provide a clearance around the pedestal 20.

The rail rollers 19 may be extended to a maximum position using the rail roller control 66 to a raised position so that the power screed is supported on the concrete 30. The screed rails 21 may then be repositioned to be supported by a next set of pedestals 20 to screed a subsequent bed of concrete 30.

Return the screed control lever to rough position, retract the rail rollers 19 so that the power screed is supported on the rails 21. Extend the leading expansion screeds 5 and move the power screed forward until it reaches the next pedestal 20, retract and extend the trailing expansion screeds 5. If the pedestal 20 is the final pedestal on the rail 21, move the power screed so it is approximately 1 foot past the pedestal 20 and place the direction lever 61 in the neutral position.

The power screed can either, 1—repositioned to the next screed location or, 2—use the transfer rails 21.

Using the transfer rails 21 raise the power screed using the feet 16. Feet 16 may also use the to raise the power screed to extract snapped on pedestals 20 high enough above the transfer rollers 17, 18 to insert the transfer rails 21, using a rail splice 31 attached to the screed rails 21. Once in place, lower the power screed onto the transfer rollers 17, 18 using the foot elevation control lever 65. Engage transfer motor 30 (optional) or slide the power screed over to next set of screed rails 21. Once positioned, raise power screed again using the foot elevation control lever 65. Remove the transfer rails 21 and lower the power screed onto the subsequent rails 21 using the foot elevation control lever 65 so that the drive rollers 8, 9 support the power screed on the rails 20. The power screed is now ready to screed the subsequent bed of concrete 30. When all screed operations are, turn the power screed off and remove from location.

It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention

It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims. 

What is claimed is:
 1. A powered screed for leveling a bed of a fluid concrete material to a desired grade, comprising: a pair of rails dimensioned to extend across a lateral extent of a bed of concrete to be screeded; a plurality of support pedestals to support the pair of rails in an elevated position above the bed of concrete; a power screed having a frame and a plurality of support rollers coupled to the frame, at least one of the plurality of support rollers is a drive roller, the plurality of support rollers configured to movably carry the power screed on the pair of rails, and the drive roller is engageable with the pair of rails to provide a motive force to move the power screed along a length of the pair of rails; a motor coupled to a transmission assembly to rotate the drive roller; and a main screed element attached to a bottom of the frame, the main screed element oriented to screed across a longitudinal extent of the bed of concrete as the power screed traverses the pair of rails.
 2. The power screed of claim 1, further comprising: a first linear actuator coupled between the frame and the main screed element, the first linear actuator operable to selective raise or lower the main screed element relative to the bed of concrete.
 3. The power screed of claim 2, further comprising: an expansion screed coupled to the main screed element, the expansion screed selectively extensible to expand a length of the main screed element to the longitudinal extent of the bed of concrete.
 4. The power screed of claim 3, further comprising a second linear actuator coupled between the frame and the expansion screed, the second linear actuator operable to selectively extend and retract the expansion screed relative the main screed element.
 5. The power screed of claim 1, further comprising: a foot moveably disposed on the frame; and an actuator coupled between the foot and the frame, the actuator operable to selectively extend the foot to support the power screed on the foot, and retract the foot so that the power screed may be supported on the pair of rails by the plurality of support rollers.
 6. The power screed of claim 1, further comprising: a vibration module attached to the main screed element, the vibration module configured to deliver a vibratory force to the main screed element that is imparted to the bed of concrete.
 7. The power screed of claim 1, wherein the plurality of support pedestals are vertically adjustable to orient the pair of rails in an alignment with a desired grade of the bed of concrete.
 8. The power screed of claim 7, further comprising: a plurality of threads at a top end of a pedestal shaft; a collar threadingly engageable with the plurality of threads to adjust a vertical height of the collar relative to the pedestal shaft; and a yoke disposed at a top end of the plurality of support pedestals, the yoke having a top opening dimensioned to receive a transverse dimension of one of the pair of rails therein, and a downwardly extending cylindrical shaft having a bore dimensioned to receive the top end of the pedestal shaft, and a length to be supported on the collar.
 9. The power screed of claim 8, further comprising, a base plate having an aperture defined in a top surface of the base plate, the aperture dimensioned to receive a bottom end of the pedestal shaft.
 10. The power screed of claim 9, wherein the aperture extends through the base plate and the bottom end of the pedestal shaft is received through the aperture and has a length to penetrate a ground surface subjacent to a bottom of the base plate.
 11. The power screed of claim 10, further comprising: an annular rim around the bottom end of the pedestal shaft, wherein the annular rim is positioned at a desired penetration depth of the pedestal shaft into the ground surface.
 12. The power screed of claim 1, further comprising: a remote controller for controlling a direction and a rate of the drive roller. 